Frame joint construction

ABSTRACT

A metallic joint is described, consisting of intersecting tubular members, which are joined together at their points of intersection in a novel manner. The joint is especially adapted for constructing a skeleton frame or lattice to be used in constructing boats or the like.

Unite tates Ptent [191 1 RAME JOINT CONSTRUCTION [76] Inventor: Everett 1. Bibi), 24225 San Pedro Ln., Carmel, Calif. 93921 22 Filed: Mar. 9, 1973 21 Appl.No.:339,698

Related US. Application Data [62] A Division of Ser. No. 94,398, Dec. 2, 1970, Pat. No.

[52] US. Cl. 403/347, 403/387 [51] Int. Cl. Fl6b 7/00 [58] Field of Search 9/6, 6.5; 114/65 R, 65 A,

l14/66.5 F, 79 R, 79 W, 81, 83, 88; 244/119; 287/49, 51, 64, 189.36 A; 52/80, 81, 309; 403/207, 346, 347, 387

[56] References Cited UNITED STATES PATENTS 2,122,300 6/1938 Smith et a1... 114/65 A [451 Nov. 19, 1974 11/1940 8/1956 ll/l96l Ferris 403/346 X Smith Urban Korf Demo

Guzelman 52/80 Primary Examiner-Lloyd L. King Assistant Examiner-Randolph A. Reese Attorney, Agent, or Firm-Isler and Ornstein I5 7] ABSTRACT A metallic joint is described, consisting of intersecting tubular members, which are joined together at their points of intersection in a novel manner. The joint is especially adapted for constructing a skeleton frame or lattice to be used in constructing boats or the like.

3 Claims, 10 Drawing Figures PAIENTE raw 1 91974 SHEU 2 BF 3 T l I PATENTEL 30v 1 91974 SHEEI 30F 3 1 FRAME JOINTCONSTRUCTION This is a division of application Ser. No. 94,398, filed Dec, 2, 1970 now U.S. Pat. 3,749,594.

In Pat. No. 2,122,300, a method of constructing a boat or the like is described, in which a skeleton frame composed of rods or tubes of metal is formed, which frame is fashioned or shaped to produce the desired cross-section and longitudinal contour of the boat, these rods or tubes being preferably welded together where they abut.

A- sheet of openwork fabric is secured, as by welding, to the inner or outer surface of the skeleton frame, and the sheet may be composed of wire mesh. In some cases, two openwork bodies or sheets may be arranged one directly upon the other with the sheets having meshes of different sizes as well as composed of lighter and heavier wires. Moreover, a large mesh sheet may be arranged on the outer surface of the skeleton frame, and a smaller mesh sheet on the inner surface thereof.

, After the sheet or sheets have been arranged on the frame, a body portion of plastic or similar material is then applied so as to imbed the frame and the said sheet or sheets therein to form smooth inner and outer surfaces whichwill define the hull and superstructure of the boat.

Several methods of applying the plastic or similar material are described, one of these methods involving spraying the plastic by means of a pressure spray, with the exposed surfaces later sanded to provide a smooth and definite contour and surface.

The plastic which is used in the aforesaid patent may be a liquid, semi-liquid, or plastic substance incorporated with asuitable binder which may also act as a reinforcing agent in constructing the boat. The plastic material may have metallic bases or wood pulp, cellulose or fibrous bases, and the patent cites, by way of example, the use of plastic wood, which the patentees use in a semi-liquid form by incorporating acetone therewith, as a solvent, in the proportions of 1% pints of the solvent to Ipound of the plastic wood.

In spraying the frame and sheets of wire mesh, by a pressure spray, it is .obviousthat a substantial portion of the plastic will "pass through the frame and wire mesh, and into the atmosphere, and is thus lost, so that the method is not economical. Moreover, if the plastic contains a volatile solvent, such as acetone, the fumes of the solvent, escaping into the atmosphere, can be hazardousto the workman and others in the area of construction.

Other disadvantages of the foregoing method include (a) the cost ofthe wire mesh sheets, as well as the labor involved in welding the wire mesh sheets to the skeleton frame, (b) the substantial increase in weight of the structure, due to the fact that the wire mesh sheetsremain in situ, and (c) the increase labor cost due to the fact that both sides of the structure must be sanded to form smooth inner 'and'outersurfaces and to reduce the overall thickness of the structure to desired uniformity.

A primary object of the invention is to provide a skeleton frame made of metallic tubes or tubing, which are interconnected or joined together in a manner which provides great strength, while maintaining the overall thickness of the frame to a uniform dimension which does not exceed the diameter of the tubes or tubing.

Another object of the invention is to provide a novel method of forming and joining the tubes which form the skeleton frame.

Other objects and advantages of my invention will be apparent during the course of the following description.

In the accompanying drawings forming a part of this specification, and in which like numerals are employed to designate like parts throughout the same,

FIG. 1 is a perspective view of a boat hull in the process of beingmanufactured by the method of the present invention;

FIG. 2 is a transverse cross-sectional view, taken on the line 2-2 of FIG. 1;

FIG. 3 is a fragmentary cross-sectional view, on an enlarged sca1e,of a portion of FIG. 2, and showing the flexible backing sheet in the process of being removed from the core; 7 Y

FIG. 4 is a fragmentary elevational view, as viewed in the direction indicated by the-line 4-4 of FIG. 3;

FIG. 5 is afragmentary cross-sectional view, on an enlarged scale, showing the application of finish layers or laminations to the reinforced foam core;

FIG. 6 is a fragmentary plan view showing one of the frame joints; 6 l

FIG. 7 is a fragmentary cross-sectional view, taken on the line 7--7 of FIG. 6;

FIG. 8 is a fragmentary the line 8-8 of FIG. 6;

FIG. 9 is a fragmentary cross-sectional view, taken on the line 9-9 of FIG. 6, and

FIG. 10 is a fragmentary cross-sectional view, taken on the linel0-l0 of FIG. 6.

cross-sectionalview, taken on Referring more particularly to FIGS. 1 to 5 inclusive joined together and welded at their points of intersection in such a manner that the-thickness of the frame at such'points of intersection is substantially the same as that of all other potions of the frame, so that the frame, to all intents and purposes, is of substantially uniform thickness throughout, such thickness corre-- sponding to the outside diameter of the tubes. The manner in which this is accomplished will be presently described.

The ribs or cross-members 12 at one side of the structure are secured at their outer ends in a gunwale member 14, while the ribs or cross-members 12 at the other side of the structure are secured at their outer ends in a similar gunwalemember 15. The inner ends of the ribs or cross-members 12 are flattened, as at 12', and these flattened ends are secured to a keel member 16. As best seen in FIGS. 1 and 2, the gunwale members 14 and 15 rest on permanently formed blocks 17 and 18 which also receive the protuberant ends of the ribs or cross-members 12.

When the skeleton frameis thus completed, a memposts 21, are brought to bear against the keel member 16. Each stanchion supports a plurality of adjustable struts or arms 22, which may be brought to bear at desired points against the member 19 to thus hold the latter against the skeleton frame.

The member 19 is preferably made of a flexible impervious material, such, for example, as linoleum, which is coated on its outer surface with wax, for a purpose to be presently described. While linoleum is a preferred material from which to form the backstop 19, other flexible, impervious materials may be used for this purpose, such as plastic sheets, with such plastic sheets being reinforced, if desired, as strength requirements may dictate. Instead of the wax coating, to which reference has been made,.thin plastic sheets, such as cellophane, may be used at the outer surface of the member 19. The member 19 must be sufficiently flexible to permit it to be conformed to the contour of the skeleton frame, yet sufficiently strong to prevent bulging of the material outwardly into the openings of the skeleton frame.

The hull is now ready for the application of the plastic or plastic material 24 in which the skeleton frame is to become embedded.

For this purpose, a fluid plastic, such as polyurethane foam, is preferably employed, and is sprayed against the frame and backstop 19 by means of a conventional spray gun 25 (see FIG. 1). Polyurethane foam has a bubbly or sudsy consistency on emanating from a spray gun, but on exposure to the atmosphere, solidifies or sets as a solid porous substance, in a fine state of cellular subdivision.

Although polyurethane foam is preferred as the plas-.

nations of sprayed-on fibreglass, or may have applied 4 members 19, inflated air envelopes or bags may be used for this purpose, such envelopes or bags being deflated after the core has been constructed, to permit removal of the backstop members.

It is thus seen that I have provided a method of constructing a boat in which the use of wire mesh sheets and their retention in'the core is obviated; in which an impervious removable backstop of flexible material is utilized during the spraying operation, to thereby obtain a smooth finish on the inside surface of the core, without requiring sanding or finishing of that side; in which the skeleton frame is utilized as a guide and control in smoothing and finishing the outer side of the core; and in which certain selected types of plastics or resins are used in forming the core, which plastics or resins have considerable buoyancy, as well as insulating qualities for resisting vibration, noise, and temperature changes.

Reference has been made above to the fact that the steel tubes of which the frame is made are joined together and welded at their points of intersection in such a manner that the thickness of the frame at such points and urea-formaldehyde type, as well as polyester and epoxy resins.

Since the open expansions of such foams are not uniformly precise, an overspray of foam is used, such overspray being depicted in somewhat exaggerated thickness, by the reference numeral 24' in FIGS. 2 and 3.

The overspray or excess of foam, after the foam has set and is fully cured, may be removed down to the frame, by either sanding, or through the use of special cutting tools.

There is thus formed a buoyant, reinforced foam core, in the shape of the boat which is being constructed, such core consisting of the plastic foam and the skeleton frame which is embedded in the foam.

When the outer surface of this core has been contoured and smoothed, the stanchions 20 and arms 22 may be removed, and the backstop member 19 dropped away from the core, as shown in FIG. 3, leaving a core, smooth on both sides, and with only the lines of tangency of the tubes of the metal frame with the inner and outer surfaces of the core exposed or substantially exposed.

Due to the wax coating of the member 19, or the cellophane sheet on the outer surface of the'member 19, the member 19 can be easily stripped away from the core, without affecting, in any way, the inner surface of I the core.

The core, or form," as it may be termed, may then be coated, both inside and outside, with layers or lamiof intersection is'substantially the same as that of all other portions of the frame, so that the frame, to all intents and purposes, is of substantially uniform thickness it will be seen that the tubes 13, at their points of intersection with the tubes 12, are deformed, through the use of heat and suitable dies, to provide notches, which are defined by a substantially rectangular seat 30, which extends substantially diametrically of the tube 13, and the dimensions of which are substantially the same as the outside diameter of the tube, and upstanding end walls 31 and 32, which are of substantially semi-circular contour.

At the same time, the lower portion of the tube 13, in the area of the notch, is extruded or shaped to provide shoulders consisting of semi-circular vertical walls 33 and 34 which are substantially tangential to the outer wall of the tube, and are interconnected with the outer wall of the tube by walls 35 and 36 of arcuate cross-section, which extend horizontally to such outer wall.

The tubes 12, at their points of intersection with the tubes 13, are similarly deformed, through the use of heat and suitable dies, to provide notches, which are defined by a substantially rectangular seat 37, which extends substantially diametrically of the tube 12, and the dimensions of which are substantially the same as the outside diameter of the tube and depending end walls 38 and 39, which are of substantially semicircular contour, and which, when the tubes 12 and 13 are nested within each other, as shown in FIG. 6, lie adjacent the walls 33 and 34 respectively.

At the same time, the upper portion of the tube 12, in the area of the notch, is extruded or shaped to provide shoulders consisting of semi-circular vertical walls 40 and 41, which are substantially tangential to the outer wall of the tube 12, and are interconnected with the outer wall of the tube 12 by walls 42 and 43 of arcuate cross-section, which extend horizontally to such outer wall.

When the tubes 12 and l3 are nested within each other, as shown in FIG. 6, the shoulders 4-0 and 41 of the tube 12 will lie adjacent the end walls 31 and 32 respectively of the tube 13, and the tubes may be welded to each other by means of welding procedures, such as fusion welding by induction heating at the joint areas.

This technique of joining has the following advantages l. The continuity of shape of each tube, in relation to the other tube, appears to be maintained at each oint.

2. A close, tight, fitting isattained at each joint, and the joint has great strength.

3. No cutting, removal, or elimination of material is required at the joint.

4, A means is provided for rapidly producing a multiplicity of joint areas in long lengths of tubing, as required in forming the skeleton frame which has been described.

5. The amount of time, material, and cost of welding is reduced to a minimum.

6. The fusion of the material at the joints, through the use of appropriate welding methods, including fusion welding by induction heating, is made possible, thereby eliminating conventional welding procedures, utilizing weld metals.

7. It permits the formation of joints at various angles of intersection, along the same length of tube.

8. It makes possible the maintenance of a uniformity of thickness at the joint, which thickness does not exceed the outside dimension of each tube.

9. It provides a space through each tube, equivalent to half the cross-sectional area of the tube, which space is available for use as a conduit for electric wire, water, fuel, air, etc.

Although the invention has been described more particularly with reference to the construction of a boat or the like, it is to be understood that it may be applied to the construction of a wide variety of other objects, including, for example, refrigerator bodies.

It is to be understood that the form of my invention, herewith shown and described, is to be taken as a preferred example of the same, and that various changes may be made in the shape, size and arrangement of parts thereof, without departing from the spirit of the invention, or the scope of the subjoined claims.

Having thus described my invention, 1 claim:

1. A metallic joint consisting of a first tube having a notch therein defined by a solid substantially rectangular seat extending substantially diametrically of said tube and upstanding solid and walls of substantially semicircular contour and each extending from the periphery of said tube to said seat, the portion of said tube below said notch being shaped to provide shoulders consisting of semi-circular solid vertical walls substantially tangential to the outer wall of the tube and having lower edges interconnected with the outer wall of the tube by solid walls of arcuate cross section which extend horizontally to said outer wall of the tube, and a second tube having a notch therein in confronting relation to the notch of said first tube and defined by a solid substantially rectangular seat extending substantially diametrically of the second tube and overlying the seat of the first tube, and depending solid end walls of substantially semi-circular contour and each extending from the periphery of said second tube to said seat, said lastnamed end walls lying substantially in contiguity with the shoulders of the first tube and being substantially coextensive in area with the areas of said shoulders, the portion of said second tube above the notch thereof being shaped to provide shoulders consisting of semi-circular solid vertical walls substantially tangential to the outer wall of the second tube and having upper edges interconnected with said last-named outer wall by solid walls of arcuate cross section which extend horizontally to the outer wall of the second tube, said last-named shoulders lying substantially in contiguity with the end walls of the notch in said first-named tube, said tubes being bonded to each other in the area of said joint.

2. A metallic joint, as defined in claim 1, wherein said tubes are of substantially the same diameter.

3. A metallic joint consisting of a first member having an external cylindrical surface, and having a notch therein defined by a solid substantially rectangular seat extending substantially diametrically of said member and end walls extending from opposite edges of said seat to said cylindrical surface, the portion of said member below said notch being shaped to provide shoulders extending downwardly from the other opposite edges of said seat and substantially tangential to said cylindrical surface, said shoulders having semicircular lower edges interconnected with said cylindrical surface by segmental walls of arcuate cross'section, and a second member having an external cylindrical surface and having a notch therein in confronting relation to the notch of the first member and defined by a solid substantially rectangular seat extending substantially diametrically of the second member and overlying the seat of the first member and end walls extending from opposite edges of the seat of the second member to the cylindrical surface of the second member, the portion of said second member above the notch thereof being shaped to provide shoulders extending upwardly from the other opposite edges of the seat of the second member, said last-named shoulders having semicircular upper edges interconnected with the cylindrical surface of the. second member by segmental walls of arcuate cross-section, said last-named shoulders lying substantially in contiguity with the end walls of the notch in said first member, said members being bonded to each other in the area of said joint.

l= l= =l= =l 

1. A metallic joint consisting of a first tube having a notch therein defined by a solid substantially rectangular seat extending substantially diametrically of said tube and upstanding solid end walls of substantially semicircular contour and each extending from the periphery of said tube to said seat, the portion of said tube below said notch being shaped to provide shoulders consisting of semi-circular solid vertical walls substantially tangential to the outer wall of the tube and having lower edges interconnected with the outer wall of the tube by solid walls of arcuate cross section which extend horizontally to said outer wall of the tube, and a second tube having a notch therein in confronting relation to the notch of said first tube and defined by a solid substantially rectangular seat extending substantially diametrically of the second tube and overlying the seat of the first tube, and depending solid end walls of substantially semi-circular contour and each extending from the periphery of said second tube to said seat, said last-named end walls lying substantially in contiguity with the shoulders of the first tube and being substantially coextensive in area with the areas of said shoulders, the portion of said second tube above the notch thereof being shaped to provide shoulders consisting of semi-circular solid vertical walls substantially tangential to the outer wall of the second tube and having upper edges interconnected with said last-named outer wall by solid walls of arcuate cross section which extend horizontally to the outer wall of the second tube, said last-named shoulders lying substantially in contiguity with the end walls of the notch in said first-named tube, said tubes being bonded to each other in the area of said joint.
 2. A metallic joint, as defined in claim 1, wherein said tubes are of substantially the same diameter.
 3. A metallic joint consisting of a first member having an external cylindrical surface, and having a notch therein defined by a solid substantially rectangular seat extending substantially diametrically of said member and end walls extending from opposite edges of said seat to said cylindrical surface, the portion of said member below said notch being shaped to provide shoulders extending downwardly from the other opposite edges of said seat and substantially tangential to said cylindrical surface, said shoulders having semi-circular lower edges interconnected with said cylindrical surface by segmental walls of arcuate cross-section, and a second member having an external cylindrical surface and having a notch therein in confronting relation to the notch of the first member and defined by a solid substantially rectangular seat extending substantially diametrically of the second member and overlying the seat of the first member and end walls extending from opposite edges of the seat of the second member to the cylindrical surface of the second member, the portion of said second member above the notch thereof being shaped to provide shoulders extending upwardly from the other opposite edges of the seat of the second member, said last-named shoulders having semi-circular upper edges interconnected with the cylindrical surface of the second member by segmental walls of arcuate cross-section, said last-named shoulders lying substantially in contiguity with the end walls of the notch in said first member, said members being bonded to each other in the area of said joint. 